Pallet

ABSTRACT

A pallet has a top, load supporting deck  2  with an obverse face and a reverse face. The reverse face of the top deck has at least one pair of pillar seats  20 . The pallet has at least one pair of pillars  12  engageable with the at least one pair of pillar seats for raising the top deck above a floor. The at least one pair of pillars  12  are spaced apart to allow the entry of a lift fork. Each pillar  12  has a first end adjacent a side of the top deck and a second end positioned inwardly from the side of the top deck, and a sectional axis  18  extending between the first and second ends. The sectional axis  18  of each pillar is positioned so as to guide the lift fork under the top deck.

FIELD OF THE INVENTION

This invention concerns pallets of the type upon which loads are placed for transfer by a forklift.

BACKGROUND OF THE INVENTION

Timber pallets are commonly constructed from a pair of 4×4 bearers joined by a top series of timber strips or boards and a bottom series of the same creating a shallow space between for the insertion of the lifting forks of a truck or loader.

Pallets lead a hard life in that misalignment of the entering forks can push the pallet out of shape, causing damage and shortening the operational life of the pallet.

In a known pallet, the design is improved by replacing the bearers with plastic pillars and placing these between two timber decks. The pillars are oval in section and arranged in three rows of three, with their longitudinal axes parallel to each other. The pillars are fastened to the timber decks with nails. This fastening is a weakness in the pallet design and adds points of possible failure.

It is an object of the invention to provide an improved pallet or to at least provide die public with a useful alternative.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents or such sources of information is not to be construed as an admission that such documents or such sources of information, in any jurisdiction, are prior art or form part of the common general knowledge in the art.

SUMMARY OF THE INVENTION

The apparatus aspect of this invention provides a pallet comprising: a top, load supporting deck having an obverse face and a reverse face, the reverse face of the top deck having at least one pair of pillar seats; at least one pair of pillars engageable with the at least one pair of pillar seats for raising the top deck above a floor, the at least one pair of pillars being spaced apart to allow the entry of a lift fork, each pillar having a first end adjacent a side of the top deck and a second end positioned inwardly from the side of the top deck, and a sectional axis extending between the first and second ends, wherein the sectional axis of each pillar is positioned so as to guide the lift fork under the top deck.

The term “comprising” as used in this specification means “consisting at least in part of”; that is to say when interpreting statements in this specification which include “comprising”, the features prefaced by this term in each statement all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in a similar manner.

Preferably, the pallet further comprises a bottom support member having an obverse face and a reverse floor face, the obverse face of the bottom support member having at least one pair of pillar seats engageable with the at least one pair of pillars.

Preferably, the at least one pair of pillars are operatively connected to the at least one pair of pillar seats of the top deck.

Preferably, the at least one pair of pillars are operatively connected to the at least one pair of pillar seats of the bottom support member.

Preferably, a perimeter of the bottom support member is substantially the same shape as a perimeter of the top deck. Preferably, the bottom support member has substantially the same size perimeter as the top deck. Preferably, the perimeter of the bottom support member and the perimeter of top deck are tetragonal.

Preferably, the bottom support member comprises a skeletal support member.

Preferably, the at least one pair of pillars comprise four corner pillars, each corner pillar positioned at or adjacent each corner of the top deck. Preferably, the sectional axis of each corner pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck. Preferably, the corner pillars have a capsular or ellipsoidal cross-section.

Preferably, the at least one pair of pillars comprise four side pillars, each side pillar positioned at or adjacent each side of the top deck and generally centrally disposed along a side of the top deck. Preferably, the sectional axis of each side pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck. Preferably, the side pillars are positioned inboard relative to any adjacent corner pillars. Preferably, the side pillars have a capsular shaped or ellipsoidal cross-section.

Preferably, the pallet further comprising a central pillar that is generally centrally disposed and not adjacent the side edges of the top deck. Preferably, the central pillar has a substantially circular cross section.

Preferably, the pillars are generally arranged in three rows of three. The rows are preferably mutually parallel.

Preferably, each pillar seat comprises a collar to provide a joining site for an end of a corresponding pillar.

When die seats are collars they may define an aperture in the top deck. In plan view, the apertures may be capsule shaped or ellipsoidal. The pillars may be solid or tubular. The pillars too my have a cross section which is capsule shaped or ellipsoidal.

Alternatively, each pillar seats may comprise a spigot that is receivable in an end of a corresponding pillar.

Preferably, the end of the spigot is substantially flat and the end of the corresponding pillar is also substantially flat to present surfaces for an adhesive joint. Preferably, the spigot comprises a step extending around the perimeter of the spigot and the pillar comprises a mating step.

Preferably, the pillar seats of the top deck project from about 5 mm to about 25 mm from the faces of the reverse face of the top deck.

Preferably, the seats of the support member project from about 5 mm to about 25 mm from the obverse face of the support member.

Preferably, each pillar seat and corresponding pillar coaxially overlap when assembled.

A preferred pallet comprises a top deck for supporting load with an obverse face and a reverse face, a bottom deck with an obverse face and a reverse ground engaging face, support pillar spigots extending from the reverse face of the top deck, support pillar spigots extending from the obverse face of the bottom deck, the spigots being arranged in pairs and a pillar extending between each spigot pair.

In a second aspect, the invention broadly consists in a pallet comprising: a top, load supporting deck hating an obverse face and a reverse face, the reverse face of the top deck having at least one pair of pillar seats; a bottom support member having an obverse face and a reverse floor face, the obverse face of the bottom support member having at least one pair of pillar seats; and a plurality of pillars; wherein the pillar seats of the top deck and the bottom support member are arranged in pairs and one pillar of the plurality of pillars extends between each pillar seat pair.

Preferably, a perimeter of the bottom support member is substantially the same shape as a perimeter of the top deck.

Preferably, the bottom support member has substantially the same size perimeter as the top deck.

Preferably, the perimeter of the bottom support member and the perimeter of top deck are tetragonal.

Preferably, the bottom support member comprises a skeletal support member.

Preferably, the at least one pair of pillars comprise four corner pillars, each corner pillar positioned at or adjacent a corner of the top deck. Preferably, the sectional axis of each corner pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck. Preferably, the corner pillars have a capsular shaped or ellipsoidal cross-section.

Preferably, the at least one pair of pillars comprise four side pillars, each side pillar positioned at or adjacent each side of the top deck and generally centrally disposed along a side of the top deck. Preferably, the sectional axis of each side pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck. Preferably, the side pillars are positioned inboard relative to any adjacent corner pillars. Preferably, the side pillars have a capsular shaped or ellipsoidal cross-section.

Preferably, the pallet further comprises a central pillar that is generally centrally disposed and not adjacent the side edges of the top deck. Preferably, the central pillar has a substantially circular cross section.

Preferably, the pillars are generally arranged in three rows of three.

Preferably, each pillar seat comprises a collar to provide a joining site for an end of a corresponding pillar.

Alternatively, each pillar seat comprises a spigot to provide a joining site for an end of a corresponding pillar. Preferably, the end of the spigot is substantially flat and the end of the corresponding pillar is also substantially flat to present surfaces for an adhesive joint. Preferably, the spigot comprises a step extending around the perimeter of the spigot and the pillar comprises a mating step.

Preferably, the pillar seats of the top deck project from about 5 mm to about 25 mm from the faces of the reverse face of the top deck.

Preferably, the seats of the support member project from about 5 mm to about 25 mm from the obverse face of the support member.

Preferably, each pillar seat and corresponding pillar coaxially overlap when assembled.

Preferably, the pillars are substantially tubular.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

As used herein the term “(s)” following a noun means the plural and/or singular form of that noun.

As used herein the term “and/or” means “and” or “or”, or where the context allows both.

The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

One preferred embodiment of the invention is now described with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a preferred embodiment pallet;

FIG. 2 is a plan view of the preferred embodiment pallet of FIG. 1;

FIG. 3 is an underneath plan view of the preferred embodiment pallet of FIG. 1;

FIG. 4 is an end view of die preferred embodiment pallet of FIG. 1;

FIG. 5 is a sectional perspective view of a pillar site in the preferred embodiment pallet;

FIG. 6 is a sectional view of a corner fragment of an alternative embodiment pallet;

FIG. 7 is an exploded view of FIG. 6; and

FIG. 8 is a diagrammatic sectional view of a pillar variant showing press fit.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring now to the drawings, in FIG. 1 the pallet is fabricated from several mouldings. The pallet has a top, load supporting deck 2 and a lower deck 4. The top deck 2 is a generally planar, tetragonal component. The top deck of the preferred embodiment is square and is about 1165×1165 mm. The top deck is preferably a solid component. Alternatively, the top deck may have one or more drain holes. The top deck has an obverse face and a reverse face. The reverse face of the top deck has at least one pair of pillar seats. In the preferred embodiment, the top deck has nine pillar seats. The pillar seats of the top deck project from about 5 mm to about 25 mm from the faces of the reverse face of the top deck. The lower deck 4 is of skeleton construction consisting of four flat edge pads 6 about 70 mm wide interconnected by a pair of intersecting ties 8. The lower deck 4 has at least one pair of pillar seats. In the preferred embodiment, the lower deck has nine pillar seats. The seats of the support member project from about 5 mm to about 25 mm from the obverse face of the support member.

With reference to FIGS. 1 to 3, the decks 2, 4 are connected by three substantially parallel rows 10 of three hollow pillars. The pillars are engageable with the pillar seats of the top deck and the pillar seats of the lower deck to raise the top deck above the floor. The pallet has outer pillars 12 and a central pillar 14 that sits at the intersection of the ties 8 of the lower deck. Adjacent outer pillars form pairs of outer pillars. The outer pillars comprise four corner pillars and four side pillars. The central pillar is substantially circular in cross section and the outer pillars are capsular in cross section, as described below. A centreline may be drawn in an x and y orientation from the centre point of the centre pillar and each pillar intersected by the x and y axis will be bisected by the centreline. Preferably, the four outer centre pillars (as marked ‘A’ in the attached image below) are positioned inboard relative to the corner pillars.

The outer pillars 12 may be ellipsoidal or capsular in cross section. When the pillars are capsular in cross section, each pillar has a cross section with parallel sides and semicircular ends. In the preferred embodiment show, the outer pillars are ellipsoidal in cross section. This shape gives them a longitudinal axis 16 which passes through the planes of the decks at 90° and a sectional axis 18 parallel to the decks which in each pillar points toward the central pillar 14. Each outer pillar has a first end positioned towards a side of the top deck and a second end positioned inwardly from the side of the top deck and towards the centre of the top deck. The sectional axis extends between the first and second ends.

The position and cross section of each pillar seat generally corresponds to the cross section of the corresponding pillar. The top deck has a central pillar seat with a circular cross section, four corner pillar sections with capsular cross sections, and four side pillar seats with capsular cross sections. Each of the corner and side pillar seats has a first end positioned towards a side of the top deck and a second end positioned inwardly from the side of the top deck. A sectional axis extends between the first and second ends of the pillar seat. When assembled, the first end, the second end, and the sectional axis of each pillar is generally aligned with the first end, the second end, and the sectional axis of each corresponding pillar seat. The side pillars marked A in FIG. 3 are arranged inboard of the perimeter of the lower deck relative to the position of the corner pillars.

The sectional axis of each corner pillar and each side pillar extends in a direction generally parallel to the top deck and towards the centre of the pallet. In the preferred embodiment, the sectional axes of the side pillars and corner pillars intersect at the central pillar. The four internal corners of the skeleton frame are radiused to accommodate the footprint of each corner pillar in order that the sectional axis of each corner pillar should lie at about 45° to the two adjacent pads 6 of the lower deck. The effect is to create a cavity 19 between the decks of about 90 mm deep which can be entered in two directions mutually at about 90° by the forks of a forklift. In the preferred embodiment, the pallet is a four-way entry pallet. That is, the forks of a forklift can enter the cavity 19 between the decks from any one of the sides of the pallet. If the entering forks are misaligned when it enters the cavity, the forks strike a curved wall of the pillar and adjustment of the pallet position relative to the forks tends to occur without damage. This will occur if the forks enter the cavity from any side of the pallet. The pillars sometimes encounter high loads such as when the pallet is in a stack and the departing forks turn or skew causing the forks to twist the pallet. For this purpose, the sites where the pillars join the top and bottom decks are modified as shown in FIG. 5. The depth of the top deck is locally increased to form a substantially frustoconical head 20. The depths of the pads are likewise locally increased to form a substantially frustoconical spigot 23. Both the frustoconical head 20 and spigot 23 have an annular shoulder 22. The hollow pillars engage the shoulders. The overlapping part 24 of the head and spigot resists sideways forces on the pillar. Glue may be applied between the pillars and pillar seats to further increase the strength of the pallet. A cup shaped liner 26 made of polymer may be used to assist the action of glue which is introduced during fabrication, as described below.

The wall thickness of the pillar is about 4 mm, whereas the thickness of the top deck and pad is about 22 mm. During assembly, as described below, individual pillars are push fitted onto the spigots of the skeletal deck. The top deck is superimposed with its spigots in register with the pillars and the parts are closed together in a press.

In FIGS. 6 and 7, an alternative embodiment of the pillars and pillar seats is shown. The pillars are hollow and the decks have apertures 28 at the pillar sites. At each pillar site, there is a spigot 30 projecting downwardly from the top deck and a corresponding spigot projecting upwardly from the bottom pad. The lip of the spigot and the lip of the pillar have complementary ramp faces 32, 34 which are arranged on opposite sides of a snap edge 36.

The pallet may have an edge rail or bumper strip (not shown). The edge rail comprises a high density impact material. Preferably, the edge rail comprises a polyurethane or high density polyethylene HDPE) material, for example.

Each of the components of the pallet is a polymeric component. In the preferred embodiment, the pillar seats are integrally formed with the top deck and the bottom support member.

A preferred sequence of assembly is as follows:

(a) Individual pillars are a push fit into the spigots in the top deck. (b) The top deck and attached pillars are superimposed on the skeleton deck with the pillars in register with the spigots of the skeleton deck. The press doses, the lips snap over edges 36 and the two decks cannot thereafter separate.

Glue may be introduced between the pillars and the pillars seats during assembly. A cup shaped liner may be used to assist the action of glue which is introduced during fabrication.

In one embodiment of the pallet, this procedure is made easier by incorporating complementary castellations 38 in the lips.

In FIG. 8, the pillar extends between spigots 30. The spigot base run up to locator height marked A is 17.5 mm from the top deck. The pillar locator height marked B is 15 mm.

In the bottom deck, the spigot base run up to locator height taken at the highest point of the bottom deck C is 4 mm. The actual pillar locator height D is 1 mm.

We have found the advantages of the above preferred embodiment to be:

1. Only three moulding tools are necessary to fabricate the pallet. 2. The strength of the pallet is easily increased by use of a glue coating in assembly. 3. The pallet has a favorable strength/weight ratio. 4. The pallet performs adequately in the four compliance tests.

The illustrations, photographs and drawings, if any, form part of the disclosure of this specification as does the description, illustrations, photographs and drawings of any associated provisional or parent specification or of any priority document, if any, all of which are imported hereinto as part of the record hereof.

Finally it is to be understood that various alterations, modifications and/or additions may be incorporated into the various constructions and arrangements or parts without departing from the scope of the invention. 

1. A pallet comprising: a top, load supporting deck hating an obverse face and a reverse face, the reverse face of the top deck having at least one pair of pillar seats; at least one pair of pillars engageable with the at least one pair of pillar seats for raising the top deck above a floor, the at least one pair of pillars being spaced apart to allow the entry of a lift fork, each pillar having a first end adjacent a side of the top deck and a second end positioned inwardly from the side of the top deck, and a sectional axis extending between the first and second ends, wherein the sectional axis of each pillar is positioned so as to guide the lift fork under the top deck.
 2. A pallet according to claim 1 wherein the pallet further comprises a bottom support member having an obverse face and a reverse floor face, the obverse face of the bottom support member having at least one pair of pillar seats engageable with the at least one pair of pillars.
 3. A pallet according to claim 1 wherein the at least one pair of pillars are operatively connected to the at least one pair of pillar seats of the top deck.
 4. A pallet according to claim 2 wherein the at least one pair of pillars are operatively connected to the at least one pair of pillar seats of the bottom support member.
 5. A pallet according to claim 2 wherein a perimeter of the bottom support member is substantially the same shape as a perimeter of the top deck.
 6. A pallet according to claim 5 wherein the bottom support member has substantially the same size perimeter as the top deck.
 7. A pallet according to claim 5 wherein the perimeter of the bottom support member and the perimeter of top deck are tetragonal.
 8. A pallet according to claim 2 wherein the bottom support member comprises a skeletal support member.
 9. A pallet according to claim 7 wherein the at least one pair of pillars comprise four corner pillars, each corner pillar positioned at or adjacent each corner of the top deck.
 10. A pallet according to claim 9 wherein the sectional axis of each corner pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck.
 11. A pallet according to claim 9 wherein the corner pillars have a capsular or ellipsoidal cross-section.
 12. A pallet according to claim 7 wherein the at least one pair of pillars comprise four side pillars, each side pillar positioned at or adjacent each side of the top deck and generally centrally disposed along a side of the top deck.
 13. A pallet according to claim 12 wherein the sectional axis of each side pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck.
 14. A pallet according to claim 12 wherein the side pillars are positioned inboard relative to any adjacent corner pillars.
 15. A pallet according to claim 12 wherein the side pillars have a capsular shaped or ellipsoidal cross-section.
 16. A pallet according to claim 1 further comprising a central pillar that is generally centrally disposed and not adjacent the side edges of the top deck.
 17. A pallet according to claim 16 wherein the pillars are generally arranged in three rows of three.
 18. A pallet according to claim 16 wherein the central pillar has a substantially circular cross section.
 19. A pallet according to claim 1 wherein each pillar seat comprises a collar to provide a joining site for an end of a corresponding pillar.
 20. A pallet according to claim 1 wherein each pillar seat comprises a spigot that is receivable in an end of a corresponding pillar.
 21. A pallet according to claim 20 wherein the end of the spigot is substantially flat and the end of the corresponding pillar is also substantially flat to present surfaces for an adhesive joint.
 22. A pallet according to claim 20 wherein the spigot comprises a step extending around the perimeter of the spigot and the pillar comprises a mating step.
 23. A pallet according to claim 1 wherein the pillar seats of the top deck project from about 5 mm to about 25 mm from the faces of the reverse face of the top deck.
 24. A pallet according to claim 2 wherein the seats of the support member project from about 5 mm to about 25 mm from the obverse face of the support member.
 25. A pallet according to claim 1 wherein each pillar seat and corresponding pillar coaxially overlap when assembled.
 26. A pallet according to claim 1 wherein the pillars are substantially tubular.
 27. A pallet comprising: a top, load supporting deck having an obverse face and a reverse face, the reverse face of the top deck having at least one pair of pillar seats; a bottom support member having an obverse face and a reverse floor face, the obverse face of the bottom support member having at least one pair of pillar seats; and a plurality of pillars; wherein the pillar seats of the top deck and the bottom support member are arranged in pairs and one pillar of the plurality of pillars extends between each pillar seat pair.
 28. A pallet according to claim 27 wherein a perimeter of the bottom support member is substantially the same shape as a perimeter of the top deck.
 29. A pallet according to claim 28 wherein the bottom support member has substantially the same size perimeter as the top deck.
 30. A pallet according to claim 28 wherein the perimeter of the bottom support member and the perimeter of top deck are tetragonal.
 31. A pallet according to claim 28 wherein the bottom support member comprises a skeletal support member.
 32. A pallet according to claim 30 wherein the at least one pair of pillars comprise four corner pillars, each corner pillar positioned at or adjacent a corner of the top deck.
 33. A pallet according to claim 32 wherein the sectional axis of each corner pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck.
 34. A pallet according to claim 32 wherein the corner pillars have a capsular shaped or ellipsoidal cross-section.
 35. A pallet according to any one of claim 30 wherein the at least one pair of pillars comprises four side pillars, each side pillar positioned at or adjacent each side of the top deck and generally centrally disposed along a side of the top deck.
 36. A pallet according to claim 35 wherein the sectional axis of each side pillar extends in a direction generally parallel to the top deck and towards the centre of the top deck.
 37. A pallet according to claim 35 wherein the side pillars are positioned inboard relative to any adjacent corner pillars.
 38. A pallet according to claim 35 wherein the side pillars have a capsule shaped or ellipsoidal cross-section.
 39. A pallet according to claim 27 further comprising a central pillar that is generally centrally disposed and not adjacent the side edges of the top deck.
 40. A pallet according to claim 39 wherein the pillars are generally arranged in three rows of three.
 41. A pallet according to claim 39 wherein the central pillar has a substantially circular cross section.
 42. A pallet according to claim 27 wherein each pillar seat comprises a collar to provide a joining site for an end of a corresponding pillar.
 43. A pallet according to claim 27 wherein each pillar seat comprises a spigot that is receivable in an end of a corresponding pillar.
 44. A pallet according to claim 42 wherein the end of the spigot is substantially flat and the end of the corresponding pillar is also substantially flat to present surfaces for an adhesive joint.
 45. A pallet according to claim 43 wherein the spigot comprises a step extending around the perimeter of the spigot and the pillar comprises a mating step.
 46. A pallet according to claim 27 wherein the pillar seats of the top deck project from about 5 mm to about 25 mm from the faces of the reverse face of the top deck.
 47. A pallet according to claim 27 wherein the seats of the support member project from about 5 mm to about 25 mm from the obverse face of the support member.
 48. A pallet according to claim 27 wherein each pillar seat and corresponding pillar coaxially overlap when assembled.
 49. A pallet according to claim 27 wherein the pillars are substantially tubular. 